Wiring module with coupling portions

ABSTRACT

A wiring module includes a plurality of conductive plates, and first coupling portions and second coupling portions that are provided on outer peripheral portions of the plurality of conductive plates and have mutually connectable shapes. In this wiring module, the plurality of conductive plates are electrically connected by coupling the first coupling portions and the second coupling portions. Therefore, changing a manner in which the conductive plates are coupled is disclosed (for example, changing the number of coupled conductive plates, the coupling positions thereof, or the coupling angles thereof).

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority of Japanese patent applicationJP2017-008400 filed on Jan. 20, 2017, the entire contents of which areincorporated herein.

TECHNICAL FIELD

The present invention relates to a wiring module including a pluralityof conductive plates.

BACKGROUND ART

JP 2016-101046A discloses a wiring module formed by stacking a pluralityof flat wiring bodies. This wiring module is a large module molded inone piece into a shape for mounting to a vehicle.

JP 2016-101046A is an example of related art.

SUMMARY

However, a wiring module molded in one piece in this manner cannot bemounted in a vehicle having a shape that is different from a shape forwhich the wiring module has been designed.

To address this, it is an object of the present design to provide awiring module capable of being used in various layouts depending on theshapes of vehicles.

To solve the foregoing problems, a wiring module according to a firstaspect includes a plurality of conductive plates, and first couplingportions and second coupling portions that are provided on outerperipheral portions of the plurality of conductive plates and havemutually connectable shapes, wherein the plurality of conductive platesare electrically connected by coupling the first coupling portions andthe second coupling portions.

A second aspect is the wiring module according to the first aspect,wherein the plurality of conductive plates have the same shape, thefirst coupling portions provided on the outer peripheral portions of theplurality of conductive plates have the same shape, and the secondcoupling portions provided on the outer peripheral portions of theplurality of conductive plates have the same shape.

A third aspect is the wiring module according to the first or secondaspect, wherein the first coupling portions and the second couplingportions each include a screwed portion, and a common screw is insertedinto the first coupling portion provided on the outer peripheral portionof one of the adjacent two conductive plates and the second couplingportion provided on the outer peripheral portion of the other to couplethe first coupling portion and the second coupling portion.

A fourth aspect is the wiring module according to the third aspect,wherein, in each of the plurality of conductive plates, the firstcoupling portion is provided at one end in a longitudinal direction, andthe second coupling portion is provided at the other end in thelongitudinal direction.

A fifth aspect is the wiring module according to the fourth aspect,wherein, in each of the plurality of conductive plates, the firstcoupling portion is provided at a corner portion at the one end, and thesecond coupling portion is provided at a corner portion at the otherend.

A sixth aspect is the wiring module according to the fourth or fifthaspect, wherein, in each of the plurality of conductive plates, at leastone of the first coupling portion and the second coupling portion isprovided at an intermediate portion in a longitudinal direction.

A seventh aspect is the wiring module according to the first or secondaspect, wherein the first coupling portions are parts of the outerperipheral portions of the plurality of conductive plates that have beenprocessed into a protruding shape, the second coupling portions areparts of the outer peripheral portions of the plurality of conductiveplates that have been processed into a recessed shape, and the firstcoupling portion provided on the outer peripheral portion of one of theadjacent two conductive plates is fitted to the second coupling portionprovided on the outer peripheral portion of the other to couple thefirst coupling portion and the second coupling portion.

An eighth aspect is the wiring module according to the seventh aspect,wherein, in each of the plurality of conductive plates, the firstcoupling portion is provided at one end in a longitudinal direction, andthe second coupling portion is provided at the other end in thelongitudinal direction.

A ninth aspect is the wiring module according to the eighth aspect,wherein, in each of the plurality of conductive plates, at least one ofthe first coupling portion and the second coupling portion is providedat an intermediate portion in a longitudinal direction.

A tenth aspect is the wiring module according to any one of the first toninth aspects, and further includes a branch conductive plate, andbranch coupling portions that are provided at at least three positionson an outer peripheral portion of the branch conductive plate and can becoupled to one of the first coupling portion or the second couplingportion.

An eleventh aspect is the wiring module according to any one of thefirst to tenth aspects, and further includes a fuse, an insulating basethat holds the fuse, a coupling portion for a fuse that is provided onan outer peripheral portion of the base and can be coupled to at leastone of the first coupling portion and the second coupling portion, and aconductive member that has a conductive path including the fuse and iselectrically connected to the conductive plate coupled via the couplingportion for a fuse.

With the first to eleventh aspects, in the wiring module, the pluralityof conductive plates are electrically connected by coupling the firstcoupling portions and the second coupling portions. Therefore, changinga manner in which the conductive plates are coupled makes it possible touse the wiring module in various layouts depending on the shapes ofvehicles.

With the second aspect, the elements of each type included in the wiringmodule have the same shape, thus making it possible to improve theproductivity.

With the third aspect, the adjacent conductive plates can be coupled viaa simple structure using a screw.

With the fourth aspect, in each of the conductive plates, the firstcoupling portion is provided at one end in the longitudinal directionand the second coupling portion is provided at the other end in thelongitudinal direction. Therefore, even when a small number ofconductive plates are used, it is easy to lay out the wiring module overa long distance.

With the fifth aspect, the first coupling portions and the secondcoupling portions are coupled at the corner portions of the conductiveplates, thus making it possible to adjust the coupling angles betweenthe conductive plates in a broad range.

With the sixth aspect, in each of the conductive plates, at least one ofthe first coupling portion and the second coupling portion is providedat an intermediate portion in the longitudinal direction. Flexibility ofthe layout of the wiring module is improved by providing the couplingportions at both ends and the intermediate portion in the longitudinaldirection in this manner.

With the seventh aspect, the first coupling portion and the secondcoupling portion are coupled via a fitting structure, and therefore, itis easy to couple the conductive plates.

With the eighth aspect, in each of the conductive plates, the firstcoupling portion is provided at one end in the longitudinal directionand the second coupling portion is provided at the other end in thelongitudinal direction. Therefore, even when a small number ofconductive plates are used, it is easy to lay out the wiring module overa long distance.

With the ninth aspect, in each of the conductive plates, at least one ofthe first coupling portion and the second coupling portion is providedat an intermediate portion in the longitudinal direction. Flexibility ofthe layout of the wiring module is improved by providing the couplingportions at both ends and the intermediate portion in the longitudinaldirection in this manner.

With the tenth aspect, the branch coupling portions capable of beingcoupled with one of the first coupling portion or the second couplingportion are provided at at least three positions on the outer peripheralportion of the branch conductive plate. Using this branch conductiveplate makes it easy to form branches in the wiring module.

With the eleventh aspect, a fuse can be easily incorporated in thewiring module.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view showing a wiring module 1.

FIG. 2 is a longitudinal cross-sectional view showing one conductiveplate 30, and a first coupling portion 10 and a second coupling portion20 that are provided on the outer peripheral portion of the conductiveplate 30.

FIG. 3 is a longitudinal cross-sectional view of the wiring module 1shown in FIG. 1.

FIG. 4 is a plan view showing a layout of a wiring module 1A.

FIG. 5 is a plan view showing a layout of a wiring module 1B.

FIG. 6 is a plan view showing a layout of a wiring module 1C.

FIG. 7 is a longitudinal cross-sectional view showing a unit module100D.

FIG. 8 is a schematic perspective view showing a wiring module 1E.

FIG. 9 is a plan view showing a layout of a wiring module 1F.

FIG. 10 is a plan view showing a layout of a wiring module 1G.

FIG. 11 is a schematic perspective view showing a configuration of aconductive portion including a fuse.

FIG. 12 is a schematic plan view showing a configuration of a conductiveportion including a fuse.

EMBODIMENTS First Embodiment

Hereinafter, a wiring module according to a first embodiment will bedescribed. FIG. 1 is a schematic perspective view showing a wiringmodule 1. FIG. 2 is a longitudinal cross-sectional view showing oneconductive plate 30, and a first coupling portion 10 and a secondcoupling portion 20 that are provided on the outer peripheral portion ofthe conductive plate 30. FIG. 3 is a longitudinal cross-sectional viewof the wiring module 1 shown in FIG. 1.

The wiring module 1 includes a plurality of conductive plates 30, andfirst coupling portions 10 and second coupling portions 20 that areprovided on the outer peripheral portions of the conductive plates 30and have mutually connectable shapes.

Hereinafter, with reference to FIGS. 1 to 3, a case will be described inwhich the wiring module 1 includes four conductive plates 30, and firstcoupling portions 10 and second coupling portions 20 that are providedon the outer peripheral portions of the four conductive plates and havemutually connectable shapes.

It should be noted that, in the example shown in FIGS. 1 to 3, thewiring module 1 is formed by stacking, one on top of the other, twoconductive plates 30 a and 30 b coupled in the horizontal direction andtwo conductive plates 30 c and 30 d coupled in the horizontal direction.Hereinafter, when the individual conductive plates 30 a to 30 d aredistinguished from one another, they are denoted by additionalalphabetical characters, and when they are not distinguished, they arereferred to merely as “conductive plates 30”. The same applies to thefirst coupling portions 10 and the second coupling portions 20.Moreover, a configuration including one conductive plate 30, and firstcoupling portions 10 and second coupling portions 20 provided on theconductive plate 30 is referred to as “unit module 100”. It should benoted that, in this embodiment, the conductive plates 30 a to 30 d havethe same shape, the first coupling portions 10 a to 10 d have the sameshape, and the second coupling portions 20 a to 20 d have the sameshape.

Each of the conductive plates 30 includes a flattened conductor 31 and acoating portion 32.

The flattened conductor 31 is formed in an elongated shape such that across section taken along a plane orthogonal to the longitudinaldirection has a flattened shape (here, a rectangular shape elongated inone direction). The flattened conductor 31 is made of a metal platehaving an elongated band shape. The flattened conductor 31 is made of amaterial such as copper, a copper alloy, aluminum, or an aluminum alloy.The flattened conductor 31 may be plated with metal such as tin ornickel.

The coating portion 32 is an insulating member for covering theflattened conductor 31 in a flattened shape. The coating portion 32 isformed by performing extrusion coating to cover the periphery of theflattened conductor 31 with a resin and then stripping off a portion ofthe coating, for example. The periphery of the flattened conductor 31 iscoated with the coating portion 32 having a uniform thickness, andtherefore, a cross section of the conductive plate 30 that is orthogonalto the longitudinal direction has a flattened shape. It should be notedthat, as shown in FIG. 2, side surfaces 311 and 312, and top surfaces313 and 314, on both sides of the flattened conductor 31 in thelongitudinal direction are exposed to the outside due to the coating,which is a portion of the coating portion 32, being stripped off.

In each of the conductive plates 30, two first coupling portions 10spaced apart from each other in the short direction are provided at oneend in the longitudinal direction, and two second coupling portions 20spaced apart from each other in the short direction are provided at theother end in the longitudinal direction. More specifically, in each ofthe conductive plates 30, two first coupling portions 10 are provided atboth corner portions at one end in the longitudinal direction, and twosecond coupling portions 20 are provided at both corner portions at theother end in the longitudinal direction.

The first coupling portions 10 each include a screwed portion 11 and acoating portion 12.

The screwed portion 11 includes a threaded hole portion 111 having arecessed shape, and an extending portion 112 that extends from thebottom of the threaded hole portion 111 in the horizontal direction. Thethreaded hole portion 111 is a female screw in which a screw thread thatis screwed on a screw 40 (male screw) when the screw 40 is insertedthereinto is formed on the inner circumferential surface. The screwedportion 11 is made of a conductive member. For example, the screwedportion 11 is made of a material such as copper, a copper alloy,aluminum, or an aluminum alloy. The screw 40 may be made of metal or aresin or the like.

The coating portion 12 is an insulating member that covers the outercircumferential surface of the screwed portion 11. The coating portion12 is formed by molding a resin around the screwed portion 11, forexample. It should be noted that a lower surface 113 on the conductiveplate 30 side (right side in FIG. 2) of the extending portion 112 of thescrewed portion 11 is not coated with the coating portion 12 and isexposed to the outside.

The screwed portion 11 is provided at one end (on the left side in FIG.2) of the conductive plate 30 in the longitudinal direction. Morespecifically, the lower surface 113 of the extending portion 112 of thescrewed portion 11 and a top surface 313 of the flattened conductor 31are joined by welding or the like. As a result, the first couplingportion 10 and the conductive plate 30 are electrically connected.

The second coupling portion 20 includes a screwed portion 21 and acoating portion 22.

The screwed portion 21 includes a threaded hole portion 211 having atubular shape, and an extending portion 212 that extends from thethreaded hole portion 211 in the horizontal direction and the downwarddirection. The threaded hole portion 211 is a tubular portion whoseinner diameter is substantially the same as that of the threaded holeportion 111 and through which the screw 40 (male screw) can be inserted.The screwed portion 21 is made of a conductive member. For example, thescrewed portion 21 is made of a material such as copper, a copper alloy,aluminum, or an aluminum alloy.

The coating portion 22 is an insulating member that covers the outercircumferential surface of the screwed portion 21. The coating portion22 is formed by molding a resin around the screwed portion 21, forexample. It should be noted that a lower surface 213 on the conductiveplate 30 side (left side in FIG. 2) of the extending portion 212 of thescrewed portion 21 is not coated with the coating portion 22 and isexposed to the outside.

The screwed portion 21 is provided at one end (on the right side in FIG.2) of the conductive plate 30 in the longitudinal direction. Morespecifically, the lower surface 213 of the extending portion 212 of thescrewed portion 21 and a top surface 314 of the flattened conductor 31are joined by welding or the like. As a result, the second couplingportion 20 and the conductive plate 30 are electrically connected.

As a result, the unit module 100 in which the first coupling portions 10and the second coupling portions 20 are joined to the conductive plate30 as shown in FIG. 2 is obtained. In the unit module 100, the topsurface 114 of the threaded hole portion 111 of the first couplingportion 10 and the lower surface 214 of the threaded hole portion 211 ofthe second coupling portion 20 are located at substantially the sameheight.

Regarding the two adjacent conductive plates 30 a and 30 b, commonscrews 40 are inserted into two second coupling portions 20 a providedon the outer peripheral portion of the conductive plate 30 a and twofirst coupling portions 10 b provided on the outer peripheral portion ofthe conductive plate 30 b, and, in this state, the two screws 40 arescrewed and fastened to two threaded hole portions 111, so that the twofirst coupling portions 10 b and the two second coupling portions 20 aare coupled. As a result, a relative positional relationship between theconductive plate 30 a and the conductive plate 30 b is fixed. In thiscoupled state, top surfaces 114 b of the threaded hole portions 111 b ofthe two first coupling portions 10 b are in contact with lower surfaces214 a of threaded hole portions 211 a of the two second couplingportions 20 a. As a result, the conductive plate 30 a and the conductiveplate 30 b are electrically connected via the two first couplingportions 10 b and the two second coupling portions 20 a.

Similarly, regarding the two adjacent conductive plates 30 c and 30 d,common screws 40 are inserted into two second coupling portions 20 cprovided on the outer peripheral portion of the conductive plate 30 cand two first coupling portions 10 d provided on the outer peripheralportion of the conductive plate 30 d, and, in this state, the two screws40 are screwed and fastened to two threaded hole portions 111 d, so thatthe two first coupling portions 10 d and the two second couplingportions 20 c are coupled. As a result, a relative positionalrelationship between the conductive plate 30 c and the conductive plate30 d is fixed. In this coupled state, top surfaces 114 d of the threadedhole portions 111 d of the two first coupling portions 10 d are incontact with lower surfaces 214 c of threaded hole portions 211 c of thetwo second coupling portions 20 c. As a result, the conductive plate 30c and the conductive plate 30 d are electrically connected via the twofirst coupling portions 10 d and the two second coupling portions 20 c.

The wiring module 1 is formed by stacking, one on top of the other, thetwo conductive plates 30 a and 30 b coupled in the horizontal directionand the two conductive plates 30 c and 30 d coupled in the horizontaldirection. In this case, for example, the two conductive plates 30 a and30 b are used as a voltage supplying conductive layer, and the twoconductive plates 30 c and 30 d are used as a grounding conductivelayer. Adhesive sheets or the like (not shown) are respectively providedbetween the conductive plates 30 a and 30 c, which are stacked one ontop of the other, and between the conductive plates 30 b and 30 d, whichare stacked one on top of the other, thus preventing the conductiveplates 30 a and 30 c and the conductive plates 30 b and 30 d from beingmisaligned in the horizontal direction.

The wiring module 1 of this embodiment is used as a wiring member forelectrically connecting a battery and a DC-DC converter, startergenerator or inverter in a vehicle, for example. In this case, forexample, after the four unit modules 100 are individually transported toan assembly factory, the wiring module 1 can be completed by couplingthe unit modules 100 in the assembly factory and then mounted in avehicle. The unit modules 100 can be individually transported in thismanner, and therefore, the transportation is facilitated compared with acase where a wiring module (e.g., wiring module described in JP2016-101046A) molded in one piece into a shape for mounting to a vehicleis transported.

In the wiring module 1 of this embodiment, the two conductive plates 30a and 30 b are electrically connected by coupling the second couplingportions 20 a and the first coupling portions 10 b. Similarly, the twoconductive plates 30 c and 30 d are electrically connected by couplingthe second coupling portions 20 c and the first coupling portions 10 d.Therefore, changing a manner in which the conductive plates 30 arecoupled (for example, changing the number of coupled conductive plates,the coupling positions thereof, or the coupling angles thereof) makes itpossible to use the wiring module 1 in various layouts. Specifically,the unit modules 100 according to this embodiment may be used in commonas components for different types of vehicles. Examples in which thelayout of the wiring module 1 is changed will be described later withreference to FIGS. 4 to 6.

In this embodiment, the conductive plates 30 have the same shape, thefirst coupling portions 10 have the same shape, and the second couplingportions 20 have the same shape. The elements of each type included inthe wiring module have the same shape in this manner, thus making itpossible to improve the productivity.

In the wiring module 1 of this embodiment, the adjacent conductiveplates 30 can be coupled via a simple structure using a screw.

In the wiring module 1 of this embodiment, in each of the conductiveplates 30, the first coupling portions 10 are provided at one end in thelongitudinal direction and the second coupling portions 20 are providedat the other end in the longitudinal direction. Therefore, even when asmall number of conductive plates 30 are used, it is easy to lay out thewiring module 1 over a long distance.

Modified Examples of First Embodiment

Although a multilayered wiring module 1 in which two conductive plates30 are stacked is described in the first embodiment, the wiring modulemay be constituted by a single layer or a plurality of layers includingthree or more layers.

FIG. 4 is a plan view showing a layout of a wiring module 1A accordingto a modified example of the first embodiment.

As shown in FIG. 4, the wiring module 1A includes eight conductiveplates 30 e to 30 l, and first coupling portions 10 e to 10 l and secondcoupling portions 20 e to 20 l that are provided on the outer peripheralportions of the eight conductive plates 30 e to 30 l and have mutuallyconnectable shapes. The conductive plates 30 are electrically connectedby coupling the first coupling portions 10 and the second couplingportions 20.

More specifically, as described below, the conductive plates 30 areconnected using a plurality of screws 40. One of the two second couplingportions 20 e provided on the outer peripheral portion of the conductiveplate 30 e and one of the two first coupling portions 10 f provided onthe outer peripheral portion of the conductive plate 30 f are coupledusing one screw 40. The two second coupling portions 20 f provided onthe outer peripheral portion of the conductive plate 30 f and the twofirst coupling portions 10 g provided on the outer peripheral portion ofthe conductive plate 30 g are coupled using two screws 40. One of thetwo second coupling portions 20 g provided on the outer peripheralportion of the conductive plate 30 g and one of the two first couplingportions 10 h provided on the outer peripheral portion of the conductiveplate 30 h are coupled using one screw 40. One of the two secondcoupling portions 20 h provided on the outer peripheral portion of theconductive plate 30 h and one of the two first coupling portions 10 iprovided on the outer peripheral portion of the conductive plate 30 iare coupled using one screw 40. One of the two second coupling portions20 i provided on the outer peripheral portion of the conductive plate 30i and one of the two first coupling portions 10 j provided on the outerperipheral portion of the conductive plate 30 j are coupled using onescrew 40. One of the two second coupling portions 20 h provided on theouter peripheral portion of the conductive plate 30 h and one of the twofirst coupling portions 10 k provided on the outer peripheral portion ofthe conductive plate 30 k are coupled using one screw 40. The two secondcoupling portions 20 k provided on the outer peripheral portion of theconductive plate 30 k and the two first coupling portions 10 l providedon the outer peripheral portion of the conductive plate 30 l are coupledusing two screws 40. As a result, wiring branches are formed between thethree conductive plates 30 h, 30 i and 30 k.

In this modified example, there are some positions at which one firstcoupling portion 10 and one second coupling portion 20 are coupled usingone screw 40 between the adjacent conductive plates 30. In this case, arelative positional relationship between the adjacent conductive plates30 can be adjusted by rotating the adjacent conductive plates 30 aroundthe one screw 40 in a state in which the screw 40 is fastened loosely.Thereafter, the screw 40 can be fastened firmly to fix the relativerelationship between the adjacent conductive plates 30.

In this modified example, in each of the conductive plates 30, two firstcoupling portions 10 are provided at the corner portions at one end inthe longitudinal direction and two second coupling portions 20 areprovided at the corner portions at the other end in the longitudinaldirection. The first coupling portions 10 and the second couplingportions 20 are coupled at the corner portions of the conductive plates30. Therefore, the coupling angles between the conductive plates 30 canbe adjusted in a broad range. The layout of the wiring module 1A ischanged as appropriate depending on the position at which the wiringmodule 1A is to be mounted. For example, this wiring module 1A ismounted in a vehicle, the coupling angles between the conductive plates30 are adjusted such that the wiring module 1A may avoid other members(e.g., console box located at substantially the center of the vehicle)in the vehicle.

FIG. 5 is a plan view showing a layout of a wiring module 1B accordingto a modified example of the first embodiment.

As shown in FIG. 5, the wiring module 1B includes three conductiveplates 30 m to 30 o, and first coupling portions 10 m to 10 o and secondcoupling portions 20 m to 20 o that are provided on the outer peripheralportions of the three conductive plates 30 m to 30 o and have mutuallyconnectable shapes. The conductive plates 30 are electrically connectedby coupling the first coupling portions 10 and the second couplingportions 20.

More specifically, as described below, the conductive plates 30 areconnected using a plurality of screws 40. One of the two first couplingportions 10 m provided on the outer peripheral portion of the conductiveplate 30 m and one of the two second coupling portions 20 n provided onthe outer peripheral portion of the conductive plate 30 n are coupledusing one screw 40. One of the two first coupling portions 10 n providedon the outer peripheral portion of the conductive plate 30 n and one ofthe two second coupling portions 20 o provided on the outer peripheralportion of the conductive plate 30 o are coupled using one screw 40.

In the wiring module 1B according to this modified example, the couplingangles between conductive plates 30 are adjusted such that the anglebetween the adjacent conductive plates 30 m and 30 n and the anglebetween the adjacent conductive plates 30 n and 30 o are minimized. Thewiring module 1B is laid out in a space-saving manner in a plan view,and thus is favorable when transported to an assembly factory.

FIG. 6 is a plan view showing a layout of a wiring module 1C accordingto a modified example of the first embodiment.

As shown in FIG. 6, the wiring module 1C includes four conductive plates30 p to 30 s, and first coupling portions 10 p to 10 s and secondcoupling portions 20 p to 20 s that are provided on the outer peripheralportions of the four conductive plates 30 p to 30 s and have mutuallyconnectable shapes. The conductive plates 30 are electrically connectedby coupling the first coupling portions 10 and the second couplingportions 20.

In the wiring module 1C, in each of the conductive plates 30, threefirst coupling portions 10 in total are provided at both corner portionsat one end in the longitudinal direction and an intermediate portion inthe longitudinal direction, and three second coupling portions 20 intotal are provided at both corner portions at the other end in thelongitudinal direction and an intermediate portion in the longitudinaldirection.

As described below, the conductive plates 30 are connected using aplurality of screws 40. One second coupling portion 20 p provided at thecorner portion out of the three second coupling portions 20 p providedon the outer circumferential portion of the conductive plate 30 p andone first coupling portion 10 q provided at the intermediate portion inthe longitudinal direction out of the three first coupling portions 10 qprovided on the outer circumferential portion of the conductive plate 30q are coupled using a screw 40. Two second coupling portions 20 qprovided at the two corner portions out of the three second couplingportions 20 q provided on the outer circumferential portion of theconductive plate 30 q and two first coupling portion 10 s provided atthe two corner portions out of the three first coupling portions 10 sprovided on the outer circumferential portion of the conductive plate 30s are coupled using two screws 40. Two second coupling portions 20 rprovided at the two corner portions out of the three second couplingportions 20 r provided on the outer circumferential portion of theconductive plate 30 r and two first coupling portion 10 q provided atthe two corner portions out of the three first coupling portions 10 qprovided on the outer circumferential portion of the conductive plate 30q are coupled using two screws 40.

In the wiring module 1C according to this modified example, in each ofthe conductive plates 30, the first coupling portions 10 and the secondcoupling portions 20 are provided at both ends and intermediate portionsin the longitudinal direction. Therefore, wiring branches can be easilyformed, and flexibility of the layout of the wiring module is improved.It should be noted that it is not essential to provide both the firstcoupling portion 10 and the second coupling portion 20 at theintermediate portions in the longitudinal direction, and at least one ofthe first coupling portion 10 and the second coupling portion 20 may beprovided at intermediate portions in the longitudinal direction.

FIG. 7 is a longitudinal cross-sectional view showing a unit module 100Daccording to a modified example of the first embodiment.

As shown in FIG. 7, the unit module 100D includes one conductive plate30D, and a first coupling portion 10D and a second coupling portion 20Dthat are provided on the conductive plate 30D.

The conductive plate 30D includes a flattened conductor 31D and acoating portion 32D. The flattened conductor 31D is made of a metalplate having an elongated band shape as is the case with the flattenedconductor 31 according to the above-mentioned first embodiment. Thecoating portion 32D is an insulating member for covering the flattenedconductor 31D in a flattened shape. It should be noted that, as shown inFIG. 7, both ends of the flattened conductor 31D in the longitudinaldirection are not covered with the coating portion 32D and are exposedto the outside.

The first coupling portions 10D includes a screwed portion 11D and acoating portion 12D. The screwed portion 11D includes a threaded holeportion 111D having a recessed shape, and an extending portion 112D thatextends from the bottom of the threaded hole portion 111D in thehorizontal direction. The coating portion 12D is an insulating memberthat covers the outer circumferential surface of the screwed portion11D. The coating portion 12D is formed by molding a resin around thescrewed portion 11D, for example. It should be noted that a top surface113D on the conductive plate 30D side (right side in FIG. 7) of theextending portion 112D of the screwed portion 11D is not coated with thecoating portion 12D and is exposed to the outside. The screwed portion11D is provided at one end (on the left side in FIG. 7) of theconductive plate 30D in the longitudinal direction. More specifically,the top surface 113D of the extending portion 112D of the screwedportion 11D and a lower surface 313D of the flattened conductor 31D arejoined by welding or the like. As a result, the first coupling portion10D and the conductive plate 30D are electrically connected.

The second coupling portion 20D includes a screwed portion 21D and acoating portion 22D. The screwed portion 21D includes a threaded holeportion 211D having a tubular shape, and an extending portion 212D thatextends from the threaded hole portion 211D in the horizontal directionand the downward direction. The coating portion 22D is an insulatingmember that covers the outer circumferential surface of the screwedportion 21D. The coating portion 22D is formed by molding a resin aroundthe screwed portion 21D, for example. It should be noted that a topsurface 213D on the conductive plate 30D side (left side in FIG. 7) ofthe extending portion 212D of the screwed portion 21D is not coated withthe coating portion 22D and is exposed to the outside. The screwedportion 21D is provided at one end (on the right side in FIG. 7) of theconductive plate 30D in the longitudinal direction. More specifically,the top surface 213D of the extending portion 212D of the screwedportion 21D and a lower surface 314D of the flattened conductor 31D arejoined by welding or the like. As a result, the second coupling portion20D and the conductive plate 30D are electrically connected.

As described in this modified example, the electrical connection formbetween the conductive plate and the first coupling portion and secondcoupling portion may be different from that of the above-mentioned firstembodiment. Various forms (e.g., connection form using not a screwstructure but a rivet) may be used as the form for coupling between thefirst coupling portion and the second coupling portion.

Second Embodiment

Next, a wiring module 1E according to a second embodiment will bedescribed. FIG. 8 is a schematic perspective view showing the wiringmodule 1E according to the second embodiment.

The wiring module 1E includes a plurality of conductive plates 30E, andfirst coupling portions 10E and second coupling portions 20E that areprovided on the outer peripheral portions of the conductive plates 30Eand have mutually connectable shapes.

Hereinafter, with reference to FIG. 8, a case will be described in whichthe wiring module 1E includes two conductive plates 30E, and firstcoupling portions 10E and second coupling portions 20E that are providedon the outer peripheral portions of the two conductive plates 30E andhave mutually connectable shapes. Hereinafter, when the individualconductive plates 30Ea and 30Eb are distinguished from each other, theyare denoted by additional alphabetical characters, and when they are notdistinguished, they are referred to merely as “conductive plates 30E”.The same applies to the first coupling portions 10E and the secondcoupling portions 20E. It should be noted that, in this embodiment, theconductive plates 30E have the same shape, the first coupling portions10E have the same shape, and the second coupling portions 20E have thesame shape.

Each of the conductive plates 30E is formed in an elongated shape suchthat a cross section taken along a plane orthogonal to the longitudinaldirection has a flattened shape (here, a rectangular shape elongated inone direction). The conductive plate 30E is made of a metal plate havingan elongated band shape. The conductive plate 30E is made of a materialsuch as copper, a copper alloy, aluminum, or an aluminum alloy. Theconductive plate 30E may be plated with metal such as tin or nickel. Asdescribed above, the conductive plate 30E according to the secondembodiment is a constituent corresponding to the flattened conductor 31according to the above-mentioned first embodiment.

In each of the conductive plates 30E, one first coupling portion 10E isprovided at the center in the short direction of one end (on the leftside in FIG. 8) in the longitudinal direction, and one second couplingportion 20E is provided at the center in the short direction of theother end (on the right side in FIG. 8) in the longitudinal direction.

The first coupling portion 10E is a part of the outer peripheral portionof the conductive plate 30E that has been processed into a protrudingshape. The second coupling portion 20E is a part of the outer peripheralportion of the conductive plate 30E that has been processed into arecessed shape. Regarding the adjacent two conductive plates 30Ea and30Eb, as indicated by long dashed double-short dashed lines in FIG. 8,the first coupling portion 10Eb provided on the outer peripheral portionof the conductive plate 30Eb is fitted to the second coupling portion20Ea provided on the outer peripheral portion of the conductive plate30Ea, and thus the first coupling portion 10Eb and the second couplingportion 20Ea are coupled. As a result, the conductive plates 30Ea and30Eb are electrically connected.

In the second embodiment, the adjacent conductive plates 30Ea and 30Ebare coupled via a fitting structure, and therefore, it is easy to couplethe conductive plates 30Ea and 30Eb without using another member forconnection (e.g., screw 40).

In the second embodiment, in each of the conductive plates 30E, thefirst coupling portion 10E is provided at one end in the longitudinaldirection, and the second coupling portion 20E is provided at the otherend in the longitudinal direction. Therefore, even when a small numberof conductive plates 30E are used, it is easy to lay out the wiringmodule 1E over a long distance.

In the second embodiment, the first coupling portion 10E has aprotruding shape whose width increases toward the leading end, and thesecond coupling portion 20E has a recessed shape whose width decreasestoward the opening portion. Therefore, when the first coupling portion10E is fitted to the second coupling portion 20E, the leading end of thefirst coupling portion 10E is locked to the opening portion of thesecond coupling portion 20E, and thus the coupling state of the adjacentconductive plates 30E is retained. In this coupling state, the lateralsurface of one conductive plate 30E on which the first coupling portion10E has been provided is in surface contact with the lateral surface ofthe other conductive plate 30E on which the second coupling portion 20Ehas been provided, and therefore, positional shifts between the adjacenttwo conductive plates 30E are suppressed. It should be noted that thefirst coupling portion and the second coupling portion may havesubstantially columnar recessed and protruding shapes as described laterwith reference to FIGS. 9 and 10, or other shapes. Even in this case,the leading end of the first coupling portion is locked to the openingportion of the second coupling portion 20, and the lateral surfaces ofthe conductive plates are in surface contact with each other, so thatthe coupling state of these conductive plates is retained.

Also in the wiring module 1E of the second embodiment, as in themodified example of the first embodiment shown in FIG. 6, at least oneof the first coupling portion 10E and the second coupling portion 20Emay be provided at the intermediate portion of the conductive plate 30Ein the longitudinal direction.

Modified Examples of Second Embodiment

FIG. 9 is a plan view showing a layout of a wiring module 1F accordingto a modified example of the second embodiment.

As shown in FIG. 9, the wiring module 1F includes: two conductive plates30F; first coupling portions 10F and second coupling portions 20F thatare provided on the outer peripheral portions of the two conductiveplates 30F and have mutually connectable shapes; a branch conductiveplate 50F; and branch coupling portions 60F that can be coupled to thesecond coupling portions 20F, two branch coupling portions 60F beingprovided on each of the four sides of the outer peripheral portion ofthe branch conductive plate 50F.

Each of the conductive plates 30F is made of a metal plate having anelongated band shape. In each of the conductive plates 30F, two firstcoupling portions 10F spaced apart from each other in the shortdirection are provided at one end in the longitudinal direction, and twosecond coupling portions 20F spaced apart from each other in the shortdirection are provided at the other end in the longitudinal direction.

Each of the first coupling portions 10F is a part of the outerperipheral portion of the conductive plate 30F that has been processedinto a protruding shape. Each of the second coupling portions 20F is apart of the outer peripheral portion of the conductive plate 30E thathas been processed into a recessed shape.

The branch conductive plate 50F is made of a metal plate havingsubstantially a rectangular shape in a plan view. Two coupling portions60F spaced apart from each other are provided on each of the four sidesof the outer periphery of the branch conductive plate 50F.

Each of the coupling portions 60F is a part of the outer peripheralportion of the branch conductive plate 50F that has been processed intoa protruding shape, and can be coupled to the second coupling portion20F of the conductive plate 30F.

Therefore, the two coupling portions 60F provided on one side of theouter periphery of the branch conductive plate 50F are fitted to twosecond coupling portions 20Fa provided on a conductive plate 30Fa, andthus the two coupling portions 60F are coupled to the two secondcoupling portions 20Fa. As a result, the branch conductive plate 50F andthe conductive plate 30Fa are electrically connected.

Similarly, the two coupling portions 60F provided on one side of theouter periphery of the branch conductive plate 50F are fitted to twosecond coupling portions 20Fb provided on a conductive plate 30Fb, andthus the two coupling portions 60F are coupled to the two secondcoupling portions 20Fb. As a result, the branch conductive plate 50F andthe conductive plate 30Fa are electrically connected.

In the wiring module 1F according to this modified example, using thebranch conductive plate 50F makes it easy to form branches.

It should be noted that an embodiment in which the coupling portions 60Fare provided on the four sides of the outer periphery of the branchconductive plate 50F has been described in this modified example, butthe coupling portions 60F may be provided at at least three positions onthe outer peripheral portion of the branch conductive plate 50F.

Although an embodiment in which the coupling portions 60F of the branchconductive plate 50F can be coupled to the second coupling portions 20Fhas been described in this modified example, an embodiment in which thecoupling portions 60F of the branch conductive plate 50F can be coupledto the first coupling portions 10F may be possible.

FIG. 10 is a plan view showing a layout of a wiring module 1G accordingto a modified example of the second embodiment. FIG. 11 is a schematicperspective view showing a configuration of a conductive portionincluding a fuse.

As shown in FIG. 10, the wiring module 1G includes: two conductiveplates 30G; first coupling portions 10G and second coupling portions 20Gthat are provided on the outer peripheral portions of the two conductiveplates 30G and have mutually connectable shapes; fuses 72G; aninsulating base 70G that holds the fuses 72G; coupling portions 80G forfuses that are provided on the outer peripheral portion of the base 70Gand can be coupled to the second coupling portions 20G; couplingportions 90G for fuses that are provided on the outer peripheral portionof the base 70G and can be coupled to the first coupling portions 10G;and a conductive member 71G that has a conductive path including thefuses 72G and is electrically connected to conductive plates coupled viathe coupling portions 80G and 90G for fuses.

Each of the conductive plates 30G are made of a metal plate having anelongated band shape. In each of the conductive plates 30G, one firstcoupling portion 10G is provided at one end in the longitudinaldirection, and one second coupling portion 20G is provided at the otherend in the longitudinal direction.

The first coupling portion 10G is a part of the outer peripheral portionof the conductive plate 30G that has been processed into a protrudingshape. The second coupling portions 20G is a part of the outerperipheral portion of the conductive plate 30G that has been processedinto a recessed shape.

The base 70G is formed into a flattened shape by molding an insulatingmaterial such as a resin around the conductive member 71G and the twofuses 72G provided at intermediate portions of the path of theconductive member 71G.

The conductive member 71G is a busbar having a branch portion 710G at anintermediate portion of the path with one end of the conductive member71G being exposed from the concave of one of the coupling portions 90Gfor fuses and the other end of the conductive member 71G being exposedfrom the convexes of the two coupling portions 80G for fuses.

The fuses 72G are provided in the sections of the conductive member 71Gbetween the branch portion 710G and the coupling portions 80G for fuses.The fuses 72G are formed by press-punching a metal plate made of a metalmaterial with a low melting point such as a zinc alloy (e.g., ZnAl) or acopper alloy (e.g., Cu—Fe based alloy), for example. The fuses 72G arenarrower than the conductive member 71G and form portions that areeasily fused due to Joule's heat when an excessive current flows.

In this modified example, the second coupling portions 20G of the twoconductive plates 30G are coupled to the two coupling portions 80G forfuses provided on the outer peripheral portion of the base 70G. As aresult, the second coupling portions 20G of the two conductive plates30G are in contact with the conductive member 71G exposed from theconvexes of the two coupling portions 80G for fuses, and thus theconductive member 71G and the two conductive plates 30G are electricallyconnected.

In this modified example, fuses can be easily incorporated in the wiringmodule 1G.

FIG. 12 is a schematic plan view showing a configuration of a conductiveportion including a fuse.

This conducive portion includes: fuses 72H; an insulating base 70H thatholds the fuses 72H; coupling portions 90H for fuses that are providedon the outer peripheral portion of the base 70H and can be coupled tofirst coupling portions of conductive plates; grooves 110H into whichterminals 210 of electric wires 200 are to be inserted; and a conductivemember 71H that has a conductive path including the fuses 72H and iselectrically connected to a conductive plate coupled via the couplingportions 90H for fuses and the electric wires 200 connected via thegrooves 110H.

The base 70H is formed into a flattened shape by molding an insulatingmaterial such as a resin around the conductive member 71H and the twofuses 72H provided at intermediate portions of the path of theconductive member 71H.

The two coupling portions 90H for fuses that are parts of the outerperipheral portion of the base 70H are provided on one side (right sidein FIG. 12) of the outer peripheral portion of the base 70H. Forexample, the first coupling portions 10G of the above-mentionedconductive plates 30G can be coupled to the two coupling portions 90Hfor fuses. The two grooves 110H into which the terminals 210 of the twoelectric wires 200 obtained by performing extrusion coating to cover acore wire with a resin can be inserted are provided on another side(left side in FIG. 12) of the outer peripheral portion of the base 70H.

The conductive member 71H is a busbar having a branch portion 710H at anintermediate portion of the path with one end of the conductive member71H being exposed from a portion of the lateral surface between thecoupling portions 90H for fuses and the other end of the conductivemember 71H being exposed from the lateral surfaces of the two grooves110H.

In this modified example, the terminals 210 of the two electric wires200 are coupled to the grooves 110H provided on the outer peripheralportion of the base 70H. As a result, the terminals 210 of the twoelectric wires 200 are in contact with the conductive member 71H exposedfrom the lateral surfaces of the two grooves 110H, and thus theconductive member 71H and the two electric wires 200 are electricallyconnected. It should be noted that an embodiment in which femaleconnection portions (two grooves 110H) are provided on the outerperipheral portion of the base 70H as a configuration for connecting theconductive member 71H and the two electric wires 200 has been describedin this modified example, but an embodiment in which male connectionportions are provided on the outer peripheral portion of the base 70H isalso possible.

Other Modified Examples

A plurality of conductive plates in a wiring module may have differentshapes unlike those in the above-mentioned first and second embodiments.Similarly, in a wiring module, first coupling portions or secondcoupling portions provided on the outer peripheral portions of theconductive plates may have different shapes.

The positions and the numbers of first coupling portions and secondcoupling portions provided on the outer peripheral portion of aconductive plate can be changed from those in the above-describedembodiment.

A connector portion to be electrically connected to an externalelectrical component may be further provided on conductive plates inaddition to first coupling portions and second coupling portions.

It should be noted that the configurations described in theabove-described embodiments and modified examples can be used incombination as appropriate as long as they are compatible with eachother.

Having described the present design in detail, the foregoing descriptionis illustrative in all aspects and the present invention is not limitedthereto. It is understood that countless modified examples notillustrated herein are conceivable without deviating from the scope ofthe present invention.

It is to be understood that the foregoing is a description of one ormore preferred exemplary embodiments of the invention. The invention isnot limited to the particular embodiment(s) disclosed herein, but ratheris defined solely by the claims below. Furthermore, the statementscontained in the foregoing description relate to particular embodimentsand are not to be construed as limitations on the scope of the inventionor on the definition of terms used in the claims, except where a term orphrase is expressly defined above. Various other embodiments and variouschanges and modifications to the disclosed embodiment(s) will becomeapparent to those skilled in the art. All such other embodiments,changes, and modifications are intended to come within the scope of theappended claims.

As used in this specification and claims, the terms “for example,”“e.g.,” “for instance,” “such as,” and “like,” and the verbs“comprising,” “having,” “including,” and their other verb forms, whenused in conjunction with a listing of one or more components or otheritems, are each to be construed as open-ended, meaning that the listingis not to be considered as excluding other, additional components oritems. Other terms are to be construed using their broadest reasonablemeaning unless they are used in a context that requires a differentinterpretation.

LIST OF REFERENCE NUMERALS

-   -   1, 1A to 1C, 1E to 1G Wiring module    -   10, 10 a to 10 d, 10 f to 10 s, 10D, 10E, 10Ea, 10Eb, 10F, 10Fa,        10Fb, 10G First coupling portion    -   20, 20 a to 20 i, 20 k, 20 m to 20 s, 20D, 20E, 20Ea, 20Eb, 20F,        20Fa, 20Fb, 20G Second coupling portion    -   30, 30 a to 30 s, 30D, 30E, 30Ea, 30Eb, 30F, 30Fa, 30Fb, 30G        Conductive plate    -   40 Screw    -   50F Branch conductive plate    -   60F Coupling portion    -   80G, 90G, 90H Coupling portion for fuse

What is claimed is:
 1. A wiring module comprising: a plurality ofconductive plates; first coupling portions and second coupling portionsthat are provided on outer peripheral portions of the plurality ofconductive plates and have mutually connectable shapes; and a commonscrew is inserted into the first coupling portion provided on the outerperipheral portion of one of the adjacent two conductive plates and thesecond coupling portion provided on the outer peripheral portion of theother to couple the first coupling portion and the second couplingportion, wherein the plurality of conductive plates are electricallyconnected by coupling the first coupling portions and the secondcoupling portions, wherein the first coupling portions and the secondcoupling portions each include a screwed portion, wherein, in each ofthe plurality of conductive plates, the first coupling portion isprovided at one end in a longitudinal direction, and the second couplingportion is provided at the other end in the longitudinal direction, andwherein, in each of the plurality of conductive plates, the firstcoupling portion is provided at a corner portion at the one end, and thesecond coupling portion is provided at a corner portion at the otherend.
 2. The wiring module according to claim 1, wherein the plurality ofconductive plates have the same shape, the first coupling portionsprovided on the outer peripheral portions of the plurality of conductiveplates have the same shape, and the second coupling portions provided onthe outer peripheral portions of the plurality of conductive plates havethe same shape.
 3. The wiring module according to claim 1, wherein, ineach of the plurality of conductive plates, at least one of the firstcoupling portion and the second coupling portion is provided at anintermediate portion in a longitudinal direction.
 4. The wiring moduleaccording to claim 1, wherein the first coupling portions are parts ofthe outer peripheral portions of the plurality of conductive plates thathave been processed into a protruding shape, the second couplingportions are parts of the outer peripheral portions of the plurality ofconductive plates that have been processed into a recessed shape, andthe first coupling portion provided on the outer peripheral portion ofone of the adjacent two conductive plates is fitted to the secondcoupling portion provided on the outer peripheral portion of the otherto couple the first coupling portion and the second coupling portion. 5.The wiring module according to claim 4, wherein, in each of theplurality of conductive plates, the first coupling portion is providedat one end in a longitudinal direction, and the second coupling portionis provided at the other end in the longitudinal direction.
 6. Thewiring module according to claim 5, wherein, in each of the plurality ofconductive plates, at least one of the first coupling portion and thesecond coupling portion is provided at an intermediate portion in alongitudinal direction.
 7. A wiring module comprising: a plurality ofconductive plates; first coupling portions and second coupling portionsthat are provided on outer peripheral portions of the plurality ofconductive plates and have mutually connectable shapes; a branchconductive plate; and branch coupling portions that are provided at atleast three positions on an outer peripheral portion of the branchconductive plate and can be coupled to one of the first coupling portionor the second coupling portion, wherein the plurality of conductiveplates are electrically connected by coupling the first couplingportions and the second coupling portions.
 8. A wiring modulecomprising: a plurality of conductive plates; first coupling portionsand second coupling portions that are provided on outer peripheralportions of the plurality of conductive plates and have mutuallyconnectable shapes; a fuse; an insulating base that holds the fuse; acoupling portion for a fuse that is provided on an outer peripheralportion of the base and can be coupled to at least one of the firstcoupling portion and the second coupling portion; and a conductivemember that has a conductive path including the fuse and is electricallyconnected to the conductive plate coupled via the coupling portion for afuse, wherein the plurality of conductive plates are electricallyconnected by coupling the first coupling portions and the secondcoupling portions.